Optimise plant performance with an integrated solution
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Optimise plant performance with an integrated solution. Bratin Roy Vice President - Industry Service TÜV SÜD South Asia. Overview. 1. Background. 2. Steps to provide integrated solution. 3. Benefit. T ÜV SÜD Group – Conventional Power Plant Solution. 4. Background.

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Optimise plant performance with an integrated solution

Optimise plant performance with an integrated solution

Bratin Roy

Vice President - Industry Service

TÜV SÜD South Asia

CPP Integrated Solution


Overview

Overview

1

Background

2

Steps to provide integrated solution

3

Benefit

TÜV SÜD Group – Conventional Power Plant Solution

4

CPP Integrated Solution


Background

Background

In today’s changing environment, fossil-fuel plant owners face significant lifecycle management challenges

Along with existing issues like price pressures due to market liberalisation, new concerns of climate change and other environmental issues have further impacted the industry

Operation and maintenance cost reductions are needed along with performance improvements along the entire lifecycle

As a result, fossil fuel power plants need to be more flexible, reliable and efficient, while cutting emissions. In some countries, government has initiated fuel-saving or energy efficiency program, which constitutes further Market Based Instruments(MBI) for plant operators to improve efficiency and reduce their fuel consumption

In India, Govt. has already approved MBIs like PAT ( Performance, Achieve & Trade Scheme)

CPP Integrated Solution


Overview1

Overview

1

Background

2

Steps to provide Integrated solution

3

Benefit

TÜV SÜD Group – Conventional Power Plant Solution

4

CPP Integrated Solution


Steps to provide integrated solution

Steps to provide integrated solution

Taking an integrated approach from beginning delivers greater benefits than the traditional project stage specific approach

Integrated solutions focus on operational and implementation synergies with due consideration of plant and market needs and demand, which often get missed in traditional component/ equipment specific approach

Condition Assessment

Operation & Maintenance – status assessments

Operation & Maintenance – in-service inspection

Risk-based inspection and maintenance

Performance Measurement

Efficiency and reliability improvement solutions

Integrated plant retrofits along with comprehensive Renovation & Modernisation Program

CPP Integrated Solution


Condition assessment

Condition Assessment

  • Condition AssessmentThese evaluations focus on establishing the current condition of assets for more precise planning of refurbishment or optimisation.

  • Condition assessments provide a comprehensive review of the status of all plant equipment

  • Risk assessments review factors influencing the operational reliability of plant components and assist in planning of refurbishment activities

  • Damage assessments are used after an incident to identify affected equipment and guide repair efforts

  • Component assessments provide an up-to-date condition status of all components and systems

CPP Integrated Solution


Optimise plant performance with an integrated solution

Operation & Maintenance – status assessment

Plant status assessment

Modern maintenance

and retrofit techniques

Benefits

  • Preventive and Predictive maintenance

  • Condition-oriented maintenance

    • Inspection planning

    • NDT program

    • Monitoring methods

    • Calculation methods (e.g. fracture mechanics calc.)

    • Remaining life assessment

    • Repair/replacement of damaged components

Full up time of the plant ensuring 100% productivity, avoiding unnecessary force shut down

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CPP Integrated Solution


Optimise plant performance with an integrated solution

Operation & Maintenance - in-service inspection

In-service inspection

Destructive Tests

Non-destructive Tests

Systems and equipment

  • Metallographic Testing

  • Creep/Stress Rupture Testing

  • Measurement of Mechanical properties

  • Microbiological analysis

  • Metallurgical Chemistry Analysis

  • VE Visual Examination

  • LP Liquid Penetrant Examination

  • MP Magnetic Particle Examination

  • UTUltrasonic Examination

  • EC Eddy Current Examination

  • RX Radiographic Examination

  • MRMetallographic Replication

  • MPI Material Positive Identification

  • HMHardness Measurements

  • TDTan-Delta Test

  • HV High Voltage Test

  • DMDimensional Examination/

  • Measurement

  • Review of operation and maintenance manual

  • Review of records

  • History of power plant

  • Hot and Cold Walk-down inspection

  • Civil, concrete and steel structures

  • Boiler

  • Balance of plant

  • Generator, Transformers

  • Turbine

  • Motors, Switch Gear Panels, Circuit Breaker, Cables, UPS, Lightning, Switchyard, Control and Instrumentation

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CPP Integrated Solution


Cpp solutions performance test for power plants and energy systems

CPP solutions: Performance test for power plants and energy systems

  • Performance test for power plants and energy systemsAchieve guaranteed performance and maximise efficiency

  • Independent assessment of technical condition of plant, e.g. at the end of O & M Contract; during operation before taking decision of retrofitting or renovation

  • Identification of shortfall/deficiencies in the efficiency and capacity of plant

  • Follow international practice and test procedure like ASME, VDI

  • Assess results and prepared detail plan of implementation for technical mediation and moderation to attain maximum efficiency and reduce operation costs

CPP Integrated Solution


Risk based inspection and maintenance

Risk-based inspection and maintenance

  • Risk-based inspection and maintenance

  • Achieve safe and cost-efficient operation of your power plants

  • Our TÜV-RoiM strategy combines reliability

  • and risk assessments with information extracted

  • from expert judgment, physical models, and

  • plant-specific and generic data

  • We base our qualitative and quantitative techniques

  • on internationally accepted standards and guidelines, and tailor the solutions to your specific concerns

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CPP Integrated Solution


Optimise plant performance with an integrated solution

Energy Efficiency assessment

Energy efficiency, productivity, reliability and stability – are intimately connected.

Fact

Procedures

  • Around 70% of the world’s power plants use coal, natural gas, oil, biomass or solid waste to generate electrical energy.

  • 7 -15 % of the power generated at fossil-fuel plants is consumed by the plant’s auxiliary systems.

  • Auxiliary systems are a major part of a power generation facility. They include all the drive power applications (pumps, fans, motors, drives), electrical balance of plant and instrumentation, control and optimization systems.

  • Much of this energy could be saved or sold to generate higher plant revenues. By improving the efficiency of each auxiliary, energy consumption of an existing facility can be reduced by 10-30%

  • Combustion Control Optimisation

  • Cooling System Heat Loss Recovery

  • Flue Gas Heat Recovery

  • Low-Rank Coal Drying

  • SootblowerOptimisation

  • Steam Turbine Design Review

  • Condenser optimization

  • Improvements and optimisation of other auxiliary systems

  • A successful energy efficiency program would require a detail technical and independent evaluation of power plant and related system evaluation, and a cost vs. benefit analysis to obtain reliable cost estimates for the options under consideration, taking into account site-specific conditions

CPP Integrated Solution


Integrated retrofitting

Integrated Retrofitting

  • Integrated retrofitting Optimise availability and reliability over the long term.

  • Component/part retrofitting is not sufficient specially when ultimate goal is total asset optimisation and highest possible generation

  • By organising, an integrated program that incorporates various upgrades across the plant, matching the

  • capabilities of any combination of main components and associate parts it delivers maximum efficiency in most cost effective life extension solution

  • With limited budget and timeline integrated retrofit solutions are a great way to explore hidden potential without the involvement of huge capital

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CPP Integrated Solution


Optimise plant performance with an integrated solution

Renovation & Modernisation

Every R & M project is unique, requiring adaptation and system expertise that depends on extensive experience.

Objective

Methods

Expected Goal

  • Achieve rated output/higher than rated Output

  • Better availability of generating equipment

  • Improved performance / efficiency and life extension of unit

  • Facilitate adoption of improved operations and maintenance practices.

  • Improvement in emission levels from thermal power plants

  • Review /Study of Design basics, Erection, first commissioning and O & M record/reports

  • Energy Audit

  • Performance testing

  • Hot and cold walk-down survey of the plant

  • Interaction with O & M staff

  • Non-destructive tests (Mechanical tests and  Electrical tests on critical components, Dynamic behavior tests)

  • Evaluation and analysis of test results

  • Preparation of R & M proposal &

  • Cost benefit analysis

  • Life Extension for another 15 to 20 years is possible

  • Increase of rated capacity 4% - 8%

  • Increase of efficiency 8%-10%

CPP Integrated Solution


Optimise plant performance with an integrated solution

Background

Steps to provide Integrated solution

Benefit

TÜV SÜD Group – Conventional Power Plant Solution

1

2

3

4

CPP Integrated Solution


Tangible benefits from integrated life cycle management

Tangible benefits from integrated life cycle management

Maximum yield over the entire life cycle

Return of investment

Designed performance

Lower costs, lesser risks

Controlled risks

Stable cash flow

Peace of Mind

Key Success Factors

CPP Integrated Solution


Overview2

Overview

Background

Steps to provide Integrated solution

Benefit

TÜV SÜD Group – Conventional Power Plant Solution

1

2

3

4

CPP Integrated Solution


Our heritage 146 years of business success

Our heritage: 146 years of business success

  • 1866

  • Establishment of a Mannheim-based steam boiler inspection association by 21 operators and owners of steam boilers, with the objective of protecting man, the environment and property against the risk emanating from a new and largely unknown form of technology

  • Today

  • TÜV SÜD continues to pursue a strategy of internationalisation and growth

  • Expansion of services in ASEAN by acquiring Singapore-based PSB Group

  • 2006

  • 1910

  • First vehicle periodic technical inspection (PTI)

  • Development of a Bavaria-wide network of vehicle inspection centres in the late 1950s

  • 1958

  • Introduction of the “TÜV mark / stamp” in Germany

  • 1926

  • Conglomeration of TÜVs from the southern part of Germany to form TÜV SÜD and the expansion of business operations into Asia

  • 1990s

  • 2009

  • Launch of Turkey-wide vehicle inspection by TÜVTURK

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Optimise plant performance with an integrated solution

TÜV SÜD in numbers: Growing from strength to strength

1

One-stop Technical Solution Provider

150

Years of Experience

800

Locations Worldwide

Million Euro in Sales Revenue 2013

1,900

Employees Worldwide

20,200

Note: Figures have been rounded off.

TÜV SÜD

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Global expertise local experience

Global expertise. Local experience.

Global Headquarters: Munich, Germany

GERMANY

INTERNATIONAL

Countries with TÜV SÜD offices

1,190 € mio

10,400 staff

750 € mio

9,800 staff

Regional headquarters

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Footprint in south asia

Footprint in South Asia

  • TÜV SÜD South Asia is a fully owned subsidiary of TÜV SÜD AG

  • Operating in India since 1995

  • Extensive network of over 32 offices including 14 labs across India, Bangladesh and Sri Lanka

  • Employee strength of over 1300

  • Over 12000 customers

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T v s d cpp global competency centre india

TÜV SÜD CPP Global Competency Centre - India

  • TÜV SÜD’s Global Competence centre extends holistic advisory services to approach technical, regulatory, jurisdictional and economical viable measures for new and existing plant such as owners engineering in-service inspection / R&M / LE

  • The competence centre has highly trained and qualified team of experts, coordinated and managed from Munich, Germany

  • The competence centre has an international global approach, with local TÜV SÜD experts & expertise involved

  • The competence centre has an extensive international experience proved by the reference list, with similar jobs completed worldwide

  • Our empanelment by CEA as a consultant for preparation of DPR report for Renovation & Modernisation, will further assist us to deliver world class services to the industry

CPP Integrated Solution


Holistic solutions across the value chain

Holistic solutions across the value chain

From feasibility and planning through to procurement, construction, commissioning, operation, maintenance, and decommissioning, TÜV SÜD conventional power services ensure improved operationalsafety, reliability and overall performance of power plants for investors, engineering, procurement and construction contractors and operators.

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Advisory services along the capital value chain

Advisory services along the capital value chain

INVESTMENT

OPERATION

Feasibility &

Planning

Refurbishment & Decommission

Construction

Commission

Procurement

In-service

Owner’s engineer

Technical advisor

Plant status assessment

Technical due diligence

QA/QC

Rehabilitation/modernization

management

Repair

supervision

LTA

Feasibility

study

Code

compliance

Welding

surveillance

Construction

supervision

Expediting

HSE

inspections

Component

certification

F4S

NDT

Risk

analysis

NDT

EIA

Plant

optimization

Compliance certification

Failure analysis

(RCFA)

O & M

management

Licensing &

consenting

Pre-qualification

Final acceptance

test

Component

certification

ISO 9001

ISO 14001

AIM / RBI

Tender & contract

management

Supplier

evaluation

Efficiency

consultancy

Claim management

In-service

inspection

Vendor quality

assurance

Design review

Design approval

Regulated

ISO 50001

Non-regulated

IEE plant certification

Performance tests

Calculation

Simulation

Noise / vibration / emissions testing

Due diligence

(TDD - technical, EDD - environmental)

Site assessment

Staff training / qualification

CPP Integrated Solution


Your business benefits maximise profits

Your Business Benefits: Maximise Profits

Increase availability, optimize performance

TÜV SÜD’s experts help you obtain professional advice in performance optimization to reduce outage time and increase your return on investment.

Strengthen

your competitive

edge

Leverage on our expertise in safety and statutory compliance for legal certainty. Third-party certification by TÜV SÜD demonstrates your commitment to quality.

Minimise risk,

improve reliability

We help you to reduce the risk of conventional power plant incidents, enhance safety for people and the environment, increase process transparency and eliminate

interface problems.

Promote efficiency, reduce emissions

Our experts’ impartial perspective fosters cost efficiency in your organisation, while their comprehensive knowledge contributes to your emissions goals.

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Contact us today

Contact us today.

[email protected]

CPP Integrated Solution


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